CN101900660A - Method for detecting and diagnosing faults of intermittent low-speed and heavy-load device - Google Patents
Method for detecting and diagnosing faults of intermittent low-speed and heavy-load device Download PDFInfo
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Abstract
The invention discloses a method for state monitoring and fault diagnosis of an intermittent large-scale low-speed and heavy-load production device, wherein the state monitoring and the fault diagnosis can not be effectively solved by utilizing the vibration signal analysis method, and the method is the technical method for carrying out the state monitoring and the fault analysis and diagnosis on the intermittent large-scale low-speed and heavy-load device through physical and chemical index detection, spectral analysis and ferrographic analysis of lubricating oil liquid (grease) used by the device. The invention provides an early wear fault diagnosis and maintenance scheme of the low-speed and heavy-load device, which can improve the accuracy of lubrication state monitoring of the low-speed and heavy-load device and the using management level of the lubricating oil (grease), save maintenance cost, prolong the service life of the device and create greater production value.
Description
Technical field
The objective of the invention is intermittent large-sized low-speed heavy-load production is carried out the problem of status monitoring and fault diagnosis, saying so more specifically, it is a kind of by to the physical and chemical index detection of the used lubricating oil of equipment (fat) and spectrum, analyzing iron spectrum to have proposed, intermittent large-sized low-speed heave-load device is carried out the technical method of status monitoring and fault analysis and diagnosis, belong to monitoring of intermittent low-speed heavy duty device status and fault diagnosis technology field.
Technical background
In modern times large-scale flow process manufacturing enterprises, the production equipment major part is that rotating speed is low, load big, bears the heave-load device of greater impact load in geneva motion.This kind equipment majority is in the abominable working environment of high temperature, many dirt, very noisy, complex structure own, and automatization level is higher.In case have an accident or fault, maintenance difficult, maintenance cycle is long, cost is high, sometimes even can cause that whole production line interrupts, causes enormous economic loss.Though traditional vibration signal monitoring technology can be used as an important means of monitoring equipment fault, but for the heave-load device of low speed, geneva motion, the vibration monitoring technology makes it be difficult to prove effective in the status monitoring of low-speed heave-load device and fault diagnosis to the insensitivity of faint low frequency signal, and it is subject to extraneous low frequency environments noise signal and disturbs, thereby can't effectively detect equipment failure hidden danger and trouble location.
At present, the heave-load device Analysis on Fault Diagnosis technology of low speed, geneva motion is used comparatively limited, therefore need do deep development to the condition monitoring and fault diagnosis technology.Use single technological means the said equipment is carried out the often not ideal even inefficacy of fault diagnosis, needs are explored the status monitoring of the heave-load device of the low speed that is in complex state, geneva motion and the new analysis-by-synthesis means of fault diagnosis.
Summary of the invention
The objective of the invention is in order to solve traditional divided oscillation signal analysis method can't effectively carry out fault diagnosis to the intermittent low-speed heave-load device problem, overcome existing divided oscillation signal analysis method to weak vibration signal extraction difficulty, the shortcoming that significant fault characteristic information is easily disturbed by noise signal has proposed a kind of method of utilizing fluid (fat) check and analysis technology that intermittent low-speed heave-load device initial failure is monitored, analyzed and diagnoses.
Fluid check and analysis technology obtains representational oil sample to used lubricating oil (fat) in the operational outfit exactly, detect and analyze, obtain the variation of the used lubricating oil of relevant devices (fat) physical and chemical index, the states of matter characteristic information of the form of wear particle, pollution and products of metamorphism, size, quantity in the oil.In view of the above analytical equipment lubricated with state of wear and predict device fault, determine the technology of equipment failure position, type and reason.For maintenance of equipment provides scientific basis, instruct enterprise to carry out the active maintenance of equipment, thereby the generation of chain damage, hang-up and major accident is avoided in the inordinate wear of prevention apparatus ahead of time, reduces equipment maintenance cost, prolongs the serviceable life of equipment.
The present invention is on the basis of detecting the conventional physical and chemical index of lubricating oil (fat), utilizes spectrum, analyzing iron spectrum technology that form, size, the quantity of wear particle, pollution and products of metamorphism in the fluid (fat) are carried out quantitative test.As shown in Figure 1, by above-mentioned analysis-by-synthesis, the position of the fault of diagnostic device and definite equipment failure and reason thus.The present invention adopts following technical scheme:
A kind of method that detects and diagnose intermittent low-speed heave-load device fault, this method by regularly take after the intermittent low-speed heave-load device oil system friction pair, before the oily filter device, tank filler, fuel outlet, the oil sample of special-purpose fuel outlet valve, and to draw oil sample or grease analysis judges whether to change oil and whether this equipment exists potential faults.
This method mainly comprises the steps:
A) regularly extract intermittent low-speed heave-load device parts, be generally after the oil system friction pair, the oil sample before the oily filter device; The quantity of sampling is determined according to test item: when unitem detects about 100mL; When carrying out multinomial visual inspection such as atomic emission spectrum and iron spectrum simultaneously and surveying generally about 300mL; When all events detects generally about 500mL;
B) composition and the content of detection oil sample viscosity number, moisture value, acid number and wearer;
C) on same sampling spot according to the comparison of the viscosity number of the viscosity number of survey oil sample, moisture value, acid number and new oil sample, moisture value, acid number, and the composition of wearer and content and new oil sample or with the comparison of measurement result before, judge whether this equipment needs to change oil and whether have potential faults;
Under same sampling spot, survey must be changed oil changing with oil viscosity value and new oil sample viscosity number greater than+15% or-20% o'clock; Survey must be changed oil surpassing at 0.5% o'clock with fluid moisture and new oil sample moisture content change; Survey is 2 o'clock comparing increase by 0.5 o'clock with the acid number of fluid with the acid number of new oil sample or detecting data, must change oil;
The emission spectrum ultimate analysis detects the content of various elements in the fluid (fat), describes the wear law of the iron that is hidden in the randomness back, copper, lead and other elements with the concentration value (ppm) of various element wear particles in the fluid, and boundary value is set; The boundary value of iron is 200ppm, and the boundary value of copper is 70ppm, and plumbous boundary value is 30ppm, and the boundary value of chromium is 10ppm, and the boundary value of tin is 15ppm; When the content of a certain metal value beyond the mark, can determine that equipment exists potential faults need shut down maintenance;
In the analyzing iron spectrum technology with heavy wear degree index I
SValue is 60 boundary values as the equipment breakdown wearing and tearing, and the value of breaking bounds should be taked treatment measures immediately; With heavy wear degree index IS value reflection equipment heavy wear degree, computing formula is as follows:
I
S＝(A
L+A
S)×(A
L-A
S)
A in the formula
LBe bulky grain district wear particle area coverage value (%), position: take from fluid inlet end on the iron spectrum sheet; A
SBe granule district wear particle area coverage value (%), position: take from the iron spectrum sheet apart from liquid outlet end 50mm place.
In the analyzing iron spectrum to the classification of wear particle shape, determine wear type, comprise 1) the abrasive particle rough surface, serious plucking, scratch is arranged, profile is irregular, a large amount of oxide coexistences are arranged, sometimes be yellow, blue annealing look, length L are adhesion scratch wear particle 2 between 10～100 μ m) smooth surface, or the band pit, what have is spherical in shape, what have is thicker, profile is irregular, and there is hole on the surface that has, defectives such as fold, length L is between 10～100 μ m, the diameter D of spherical abrasive particle is between 1～5 μ m, other shape abrasive particles L/D about 4～10 for fatigue wear particle 3) abrasive particle is the cutting shape, can present spiral fashion, arc, length is in 100 μ m, width is cutting abrasion particle 4 with at 5 μ m) particle is the fines of submicron order, what tawny was deposited in iron spectrum sheet endpiece in flakes is the corrosive wear particle;
Wear type by abrasive particle is judged the abrading section: 1) adhesion scratch wear particle results from the adhesive wear between gearing mesh face tooth top and pitch circle, tooth root and the pitch circle; 2) the fatigue wear particle results from rolling contact fatigue crackle or gearing mesh face pitch circle place; 3) the cutting abrasion particle results from surface of friction pair and destroys or have a pollutant such as sand grains; 4) the corrosive wear particle illustrates and has acidic materials in the oil or cause the wearing and tearing of friction pair metallic material corrosion by environment;
Description of drawings
A kind of analysis and judgement block scheme that detects and diagnose the method for intermittent low-speed heave-load device fault of Fig. 1.
Aluminium alloy skimming wear particle in Fig. 2 filter sediment.
Aluminium alloy wear particle in Fig. 3 filter sediment has a spot of paint film organic component on it.
The spectrogram of Fig. 4 draft tube inwall attachment
Embodiment
Content in conjunction with the inventive method provides following examples:
Embodiment 1:
Regular passage of certain shipping company is in Shanghai---the van container wheel between the Japanese harbour, when having adorned goods preparation departure, the chief engineer finds to have occurred a large amount of large scale metal worn particles on oil filter, for guaranteeing shipping navigation safety, the captain orders to stop departure.
If this flight can not set out smoothly, this shipping company may face the tremendous economic loss from three aspects: at first be that goods can not arrive the destination on time, the carrier will pay huge promise breaking indemnity; Secondly this ship needs censorship immediately, so that investigate thoroughly problem, shipping company also will bear the huge loss of suspending except that will paying high maintenance cost for this reason; It is three for by fulfiling this contract of carriage approximately, must be immediately in addition chartering only carry, this shipping company pays a charterage again in addition and uses for this reason.More than three losses add up, estimate up to more than millions of units.
Because of essential, for meeting the standard of zero tolerance, this flight crew advises down at this end,
1) fresh oil that rapidly main frame is used and after extracting sample, deliver to the laboratory and carry out identification and analysis with system oil;
2) laboratory by general marine diesel test item to fresh oil with carrying out conventional physical and chemical index analysis and spectrum, analyzing iron spectrum with oil, analyzing and testing result's (seeing Table 1.1. table 1.2. table 1.3.);
Table 1.1. diesel engine main frame lubricating oil physical and chemical index analysis result
| Project | Fresh oil | Using system oil |
| Outward appearance | Brown transparent | Black non transparent |
| 100 ℃ of kinematic viscosity mm 2/s | 13.89 | 14.11 |
| Moisture content % | Do not have | 0.20 |
| Total acid number mgKOH/g | 15.62 | 14.29 |
Table 1.2. main frame lubricating oil spectral element analysis result (unit: ppm)
| Element | Fresh oil | Using oil | Element | Fresh oil | Using oil | Element | Fresh oil | Using oil |
| Fe | 2.0 | 35 | Si | 8 | 10 | Mg | 21 | 25 |
| Cu | 0.0 | 35 | Na | 5.4 | 30 | Ca | 9700 | 8130 |
| Pb | 0.0 | 2.8 | V | 0.0 | 9.4 | Zn | 589 | 471 |
| Al | 0.0 | 2.9 | Ba | 0.1 | 1.9 | P | 463 | 396 |
| Ni | 0.6 | 6.3 | K | 1.4 | 3.1 |
Table 1.3. main frame is being used the system oil analyzing iron spectrum
3) analytical table 1.1. oil sample viscosity rate of change (14.11-13.89)/13.89=1.56%＜15%; Moisture 0.2＜0.5; Total acid number lowers, and system is normal with oily physical and chemical index as fully visible;
4) the visible various constituent contents of spectral element analysis value all not beyond the mark among the analytical table 1.2.;
5) the analyzing iron spectrum result does not see the index of obvious value beyond the mark yet among the analytical table 1.3.;
6) then the laboratory metallic particles on the oil filter is analyzed.Find that these deposit appearance are the loose solid of the opaque fibre-bearing matter of black, as seen range estimation obviously contains more white and aeneous large scale metallic particles, and indivedual coating agent which has to be dissolved in alcohol before use shape materials are wherein arranged.With solvent cleaning filter sediment, discard behind the solvent the sampling of metal powder mixing, place on the iron spectrum sheet, respectively with heating with do not heat two kinds of modes and handle, compose microscopically at iron and carefully carry out the abrasive particle image analysis.The result shows that the metallic particles principal ingredient is aluminium alloy and aldary, as shown in Figures 2 and 3.
Wherein based on serious skimming wear particle, other has a small amount of fatigue wear particle, but does not see the Babbit metal particle, proves that thus these abrasive particles are not to derive from the main frame bearing.
Captain and chief engineer are according to above analysis report and combine oneself the practical experience of enriching, and think that the residue reliable life of main frame bearing is enough to support the voyage in a week, orders to depart immediately.Simultaneously they have also found the source of abrasive particle rapidly and accurately according to analysis report---from certain drive disk assembly in the reducer casing, open and inspect the back and find that these parts rupture because of heavy wear, more renew accessory after, fault is able to thorough solution.
Embodiment 2:
The major accident of bent axle locking, piston scraping has just taken place in certain import diesel motor tens hours after overhaul.Warp is all no problem with accessory and assembling that the repairing unit gets in touch definite engine.Further suspection may be that engine lubricated has problem: perhaps used wrong oil, oil leab has not been cleaned up when perhaps engine assembles.But repair unit and confirm that above-mentioned two kinds of situations all do not exist.So have impurity to enter in the oil leab when doubtful point is focused on whether engine operation, but after checking air cleaner, confirm that it is working properly, parts do not clean up so suspicious points concentrates on engine when assembling.After strip inspection finds that the engine lubrication oil duct stops up, the inwall of draft tube has the inhomogeneous dope of black, and user and when repairing unit and all being reflected in engine overhaul, once utilizes lapping compound that draft tube was polished.Do not clean draft tube when therefore doubtful point focuses on the engine assembling, or cleaning is unclean, machine oil is polluted, and causes power failure.For verifying above-mentioned diagnosis 1) residue in the diesel motor draft tube has been advanced sampling; 2) utilize spectral element analysis and analyzing iron spectrum to draw oil sample and detect.
(1) emission spectrographic analysis of sample
With draw oil sample utilize 0# mark oil dilution after, element in the oil sample and content thereof are analyzed.Table 2.1. is the result of emission spectrographic analysis.
Emission spectrographic analysis result (the unit: ppm) of the attachment of table 2.1. draft tube inwall
| Element | Measured value | Element | Measured value | Element | Measured value |
| Fe | 228 | Si | 79 | Ni | 11 |
| Cu | 520 | Mo | 6 | Na | 96 |
| Pb | 15 | Al | 166 | Zn | 252 |
| Cr | 3 | Mn | 5 | P | 252 |
| Sn | 19 | Ca | 774 | B | 129 |
| Ba | 8 | Mg | 18 |
Can find in engine charge inside pipe wall attachment, to contain elements such as a large amount of iron, copper, silicon by the data in the table, and the value of breaking bounds.With the tamper in the engine oil duct being analyzed, conform to result in the table 1 with quadrat method.Therefore, emission spectrographic analysis shows that attachment and the interior tamper of oil leab in the engine air inlet tube belong to same pollutant.
(2) analyzing iron spectrum of sample
Table 2.2. analyzes the attachment qualitative result of iron spectrum to the draft tube inwall for utilizing.
The analyzing iron spectrum result of table 2.2. draft tube inwall attachment
As shown in Figure 4, find in the attachment of engine charge inside pipe wall, to contain a large amount of iron, copper and gravel particle by analyzing iron spectrum, and the size of grit and copper abrasive dust is bigger.Use the same method the tamper in the engine oil duct is carried out analyzing iron spectrum, its result is similar to the result of table 2.2..Be distributed with grit and the copper abrasive dust of a large amount of sizes on the spectrum sheet at the 10-60 micron.Therefore, analyzing iron spectrum confirms that attachment and the interior tamper of oil leab in the engine air inlet tube belong to a kind of pollutant together.
Find by emission spectrum and analyzing iron spectrum, in attachment in the engine air inlet tube and the tamper in the oil leab a large amount of pollutants are arranged, more hard gravel particle is arranged in these pollutants, and it remains in the lapping compound on the tube wall when being mainly derived from the draft tube polishing.Because after the maintenance, draft tube is not cleaned up, the lapping compound that residues on the pipeline is blended in the oil, when oil lubricating cylinder, bent axle, these sneak into the large scale hard particles in the oil, on surface of friction pair, produce serious abrasive wear, thereby caused the generation of scuffing of cylinder bore and seize and accident.
Embodiment 3:
Certain enterprise newly buys three air compressor, and just having debug finishes came into operation less than 40 hours, the disorderly closedown that causes because of seizure of piston successively occurred.For failure cause is made analysis and judgement, the user respectively gets the 250mL sample from three units respectively and delivers to the oil analysis laboratory, to sample appearance, and viscosity, moisture, physical and chemical index such as acid number and spectral element have been carried out check and analysis, and the result is as follows:
Table 3.1. analysis of oil is summary sheet as a result
| Project | Fresh oil | 1# unit sample | 2# unit sample | 3# unit sample |
| Outward appearance | Water white transparency | Dark-brown has peculiar smell | Dark-brown has peculiar smell | Dark-brown has peculiar smell |
| 40 ℃ of kinematic viscosity mm2/s | 98.96 | 111.6 | 96.14 | 131.6 |
| Moisture % | Do not have | 0.18 | 0.23 | 0.24 |
| Total acid number mgKOH/g | 0.03 | 3.51 | 1.10 | 5.58 |
| Spectral element is divided P mg/kg | - | 178 | 150 | 173 |
1) contrasting with oil and fresh oil, outward appearance is obviously different, and experienced analyst is easy to judge that from color and smell oxidation reaction has taken place oil sample.
2) by 1) can at first carry out the total acid number test to sample, three are all raising increasing degree value 0.5 all beyond the mark significantly than fresh oil with oily acid number test result as seen from the above table;
3) also obviously raise at liquid water content with oil, and value beyond the mark.
4) content of visible phosphorus obviously increases other no abnormality seens in the spectral element analysis.
Learn that by understanding some component surface of these pneumatics units will pass through the phosphoric acid intensive treatment earlier, after acidifying, also need on request to neutralize, after being washed to neutrality, can assemble again with alkali with user communication.But lacked in the actual production with this step of alkali neutralizing acid, only water has simply cleaned after pickling, has just carried out component-assembled, has just directly added first charge of oil then.Therefore remaining acid and water pollutes fresh oil soon in the system, and under the effect of acid, the rapid oxidation of oil product causes acid number and viscosity significantly to raise, and has caused this disorderly closedown.In view of the above, advise according to analysis result in the laboratory: reply equipment thoroughly cleans, clean up to standard after, charge of oil start again again.The user is shone according to after the suggestion operations of laboratory, and equipment has recovered normal operation again.
Above example proves, as long as method is proper, by can just finding potential or emerging problem in early days what fault took place to the analysis of wear particle in conventional physical and chemical index detection of fluid (fat) and the fluid, this has special meaning for Preventive Equipment Maintenance.Self-evident, with low-speed heave-load device in analysis combination with wear particle in the monitoring of the index of quality of lubricating oil and the oil, be formed on the low-speed heavy duty device status monitoring system of reciprocal causation to a certain extent, for the early warning level that improves the low-speed heave-load device fault, formulate science more drain period and equipment maintenance plan significant.
Claims (1)
1. one kind is detected and the method for diagnosis intermittent low-speed heave-load device fault, it is characterized in that: this method by regularly take after the intermittent low-speed heave-load device oil system friction pair, before the oily filter device, tank filler, fuel outlet, the oil sample of special-purpose fuel outlet valve, and to draw oil sample or grease analysis judges whether to change oil and whether this equipment exists potential faults.
Mainly comprise the steps:
A) regularly extract in the intermittent low-speed heave-load device parts, be generally after the oil system friction pair, the oil sample before the oily filter device;
B) composition and the content of detection oil sample viscosity number, moisture value, acid number and wearer;
C) on same sampling spot according to the comparison of the viscosity number of the viscosity number of survey oil sample, moisture value, acid number and new oil sample, moisture value, acid number, and the composition of wearer and content and new oil sample or whether need to change oil and whether have potential faults with this equipment of relatively judging of measurement result before;
Under same sampling spot, survey must be changed oil changing with oil viscosity value and new oil sample viscosity number greater than+15% or-20% o'clock; Survey must be changed oil surpassing at 0.5% o'clock with fluid moisture and new oil sample moisture content change; Survey is 2 o'clock comparing increase by 0.5 o'clock with the acid number of fluid with the acid number of new oil sample or detecting data, must change oil;
The emission spectrum ultimate analysis detects the content of various elements in the fluid (fat), describes the wear law of the iron that is hidden in the randomness back, copper, lead and other elements with the concentration value (ppm) of various element wear particles in the fluid, and boundary value is set; The boundary value of iron is 200ppm, and the boundary value of copper is 70ppm, and plumbous boundary value is 30ppm, and the boundary value of chromium is 10ppm, and the boundary value of tin is 15ppm; When the content of a certain metal value beyond the mark, can determine that equipment exists potential faults need shut down maintenance;
In the analyzing iron spectrum technology with heavy wear degree index I
SValue is 60 boundary values as the equipment breakdown wearing and tearing, and the value of breaking bounds should be taked treatment measures immediately; In the analyzing iron spectrum to the classification of wear particle shape, determine wear type, comprise 1) the abrasive particle rough surface, serious plucking, scratch is arranged, profile is irregular, a large amount of oxide coexistences are arranged, sometimes be yellow, blue annealing look, length L are adhesion scratch wear particle 2 between 10～100 μ m) smooth surface, or the band pit, what have is spherical in shape, what have is thicker, profile is irregular, and there is hole on the surface that has, defectives such as fold, length L is between 10～100 μ m, the diameter D of spherical abrasive particle is between 1～5 μ m, other shape abrasive particles L/D about 4～10 for fatigue wear particle 3) abrasive particle is the cutting shape, can present spiral fashion, arc, length is in 100 μ m, width is cutting abrasion particle 4 with at 5 μ m) particle is the fines of submicron order, what tawny was deposited in iron spectrum sheet endpiece in flakes is the corrosive wear particle;
Wear type by abrasive particle is judged the abrading section: 1) adhesion scratch wear particle results from the adhesive wear between gearing mesh face tooth top and pitch circle, tooth root and the pitch circle; 2) the fatigue wear particle results from rolling contact fatigue crackle or gearing mesh face pitch circle place; 3) the cutting abrasion particle results from surface of friction pair and destroys or have a pollutant such as sand grains; 4) the corrosive wear particle illustrates and has acidic materials in the oil or cause the wearing and tearing of friction pair metallic material corrosion by environment.
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| CN102539292A (en) * | 2010-12-24 | 2012-07-04 | 中国人民解放军91872部队 | Abnormal abrasion monitoring system and method for boat motive power system |
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| CN102169078A (en) * | 2010-12-23 | 2011-08-31 | 中国神华能源股份有限公司 | Equipment quality control method for employing rotary ferrograph |
| CN102539292A (en) * | 2010-12-24 | 2012-07-04 | 中国人民解放军91872部队 | Abnormal abrasion monitoring system and method for boat motive power system |
| CN103454184A (en) * | 2013-08-20 | 2013-12-18 | 第一拖拉机股份有限公司 | Method for judging faults of bearing bush part inside medium-and-large diesel engine |
| CN106471475A (en) * | 2014-04-11 | 2017-03-01 | 哈佛蒸汽锅炉检验和保险公司 | Model to improve the reliability prediction in future based on system operatio and performance data |
| CN106482938B (en) * | 2016-10-14 | 2018-08-03 | 温州大学 | Brake fluid system multi-source fusion failure predicting method based on GA-BP networks |
| CN106482938A (en) * | 2016-10-14 | 2017-03-08 | 温州大学 | Brake fluid system multi-source fusion fault predicting method based on GA BP network |
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| CN110346541A (en) * | 2019-07-29 | 2019-10-18 | 广州机械科学研究院有限公司 | A kind of diagnostic analysis method that mechanical equipment lubrication system oil product is misused or used with |
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